Technical Analysis of the Ceramic-Rubber-Steel Triple-Composite Wear Liner
The Wear-Resistant Ceramic-Rubber-Steel Triple-Composite Wear Liner is a high-performance composite material engineered through vulcanization to integrate the high hardness of alumina ceramic, the high elasticity of rubber, and the mechanical strength of steel into a unified structure. Its design enables synergistic protection: the ceramic layer resists abrasion, the rubber layer absorbs impact energy, and the steel plate provides structural support and easy installation. The typical manufacturing process involves pre-bonding ceramic blocks (Al₂O₃ content ≥95%) to a rubber layer using high-strength adhesive, followed by vulcanization with a steel plate under high temperature and pressure, ensuring an interlayer peel strength ≥30 N/mm². This material is designed for severe abrasion and high-impact conditions, such as material handling systems in mining, power, and metallurgical industries.
The liner's performance is defined by precise metrics of each component. The ceramic layer typically uses alumina with 95% or higher purity, achieving a Rockwell hardness ≥85 HRA and wear resistance approximately 266 times that of manganese steel. The intermediate rubber layer provides cushioning and is formulated to retain elasticity within a temperature range of ‑40 °C to 120 °C, with anti-aging and anti-tear properties (tear strength ≥30 kN/m). The backing steel plate thickness ranges from 4 to 10 mm, customizable based on load requirements. The composite liner has an overall density of about 5.6 g/cm³, reducing weight by approximately 35% compared to all-steel liners, thereby lowering equipment load. In standardized tests, its impact resistance withstands repeated impacts with kinetic energy up to 50 J without ceramic detachment.
In industrial applications, this liner significantly extends equipment service life and reduces overall maintenance costs. In coal-fired power plant coal chutes, its service life reaches 24‑36 months, representing an increase of over 300% compared to traditional 16Mn steel plates (approximately 6 months). In iron ore crusher feed chutes, it reduces downtime frequency due to impact, lowering annual maintenance costs by about 40%. Furthermore, in cement plant raw mill outlet ducts, its anti-scaling and resistance to particle scouring ensure stable system airflow. Installation typically employs bolting or welding to the substrate, and wear condition can be monitored via acoustic detection, enabling predictive maintenance.
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